The Shell Polymers Monaca Site will be a world-scale petrochemical plant in Western Pennsylvania that upgrades locally-produced ethane from Marcellus and Utica shale formations gas production to make polyethylene. The petrochemical complex will consist of a world-scale Ethane Cracker Unit (ECU), multiple polyethylene (PE) units, PE logistics and supporting OSBL (utilities, general facilities, storage, and hydrocarbon logistics). The FID (Final Investment Decision) was made in Q2 2016 and the project is now in Execute Phase. As construction of the site progresses, the site is now growing to support Commissioning and Start-Up activities and prepare for full operation in the early 2020s. Not only are we building a world-class asset, we're building a world-class asset organization. This position is critical to the mission of team, and this will promise to be a once-in-a-lifetime experience.
The position will work in the Engineering group within a combined department consisting of: Engineering, Maintenance, Projects and Turnarounds. The successful candidate will provide technical support to plant/asset operations at the Penn Chem Plant as well as provide engineering technical support through Commissioning and Startup (CSU) in support of the "One Team" delivery model between the Asset and the Project.
In the project support role, the successful candidate will provide technical support in the pressure equipment discipline including initial construction and commissioning and startup activities. The successful candidate will establish inspection & engineering requirements and audit/direct work performed by contractors to ensure technical accuracy and adherence to project premises, cost and schedule requirements.
In the asset technical support role, the successful candidate will be involved in a variety of activities in direct support of plant operations, including but not limited to ensuring asset integrity and driving competitiveness, troubleshooting, conducting audits, providing advice on recommended operation and maintenance and inspection of pressure equipment, defining maintenance and inspection strategies, participating in RBI and RCM studies, investigating reliability and safety incidents, and help supporting turnaround activities.
The Corrosion and Materials Engineer is expected to be able to provide:
- Support to Project & Asset team including:
- Shutdown planning and risk-based assessments
- Material specification and prequalification
- inspection, repair recommendations, and overall Quality assurance for turnarounds
- Material failure investigations
- Provide troubleshooting and proactive technical support on materials issues related to process corrosion control and metallurgy for MOC's, PHA studies, plant changes, and new projects.
- Coordinate the development and updating of unit Corrosion Control Documents (CCD's) and Corrosion & Materials Diagrams (CMD's).
- Using CCD's, establish and update lists of key PEI integrity operating windows (IOW's) and communicate to Ensure Safe Production (ESP) work process to include in unit ESP variable tables and to ensure that these IOW's are properly monitored, and exceedances reported as part of M&CC.
- Provide material selection and technical to assist process engineers, performance specialists, and PEI Inspectors in day-to-day activities related to metallurgy, welding, and corrosion control.
- Provide project support/quality assurance for materials selection, understanding the process parameters impacting corrosion and equipment life.
- Coordinate development of training materials and methods for PEI and CCD knowledge transfer to operations, engineering, maintenance, and inspection personnel.
- Working with PEI inspectors and engineers, develop and integrate CCD recommendations into piping and equipment inspection strategies.
- Support the development of risk-based inspection plans based on corrosion mechanisms of interest.
- Coordinate development of data sheets for injection/mix points, identify equipment in environmental cracking service, and assist PEI inspectors in establishing inspection intervals for injection/mix points and environmental cracking inspections.
- Coordinate corrosion monitoring, data gathering and their subsequent use for inspection planning. Provide technical input to chemical inhibitor programs, boiler feedwater, and cooling water treatment programs, and other chemical treatment programs.
- Assist in performing root cause analysis, perform/coordinate failure analysis activities, and recommend mitigation methods for corrosion and materials issues, including repair strategies and replacement decisions.
- Network with other Corrosion & Materials Engineers in Shell/Motiva or professional organizations to assess appropriate application of high value-added M&C technologies to enhance our business.
- Establish competency requirements / profiles for both the team and site technical support personnel.
- Global training to support the competency requirements.
- Guidance and ownership of technology development, engineering standards, and best practices.
Shell is a global group of energy and petrochemicals companies with over 90,000 employees in more than 70 countries and territories. In the US, we have operated for over a century and are a major oil and gas producer onshore and in the Gulf of Mexico, a recognized innovator in exploration and production technology, and a leading manufacturer and marketer of fuels, natural gas and petrochemicals. We deliver energy responsibly; operate safely with respect to our neighbours and work to minimize our environmental impact. We are in search of remarkable people who will thrive in a diverse and inclusive work environment to deliver exciting projects locally and globally. People who are passionate about exploring new frontiers. Innovators and pioneers. People with the drive to help shape our future. Because remarkable people achieve remarkable things.
- Must have legal authorization to work in the US on a full-time basis for anyone other than current employer.
- Bachelor of Science or higher in Chemical, Materials Engineering or equivalent.
- Minimum ten (10+) years of professional experience in the Corrosion and Materials discipline.
- Ethylene and/or Polyethylene Plant experience a major plus; experience in defining and leading inspection and integrity plans is a plus.
- Experience with Pennsylvania Codes and Standards a plus
- Experience in day to day support of operating facilities; experience in designing and implementing small projects
- Knowledge of continuous improvement and Causal Learning
- Knowledge of API, ASME, ISO, DEP standards for design, fabrication, repair, maintenance and inspection standards
- Experience with Management of Change Knowledge of budgeting and contracting & procurement contract setup
- Capable coaching skills with crafts and front-line leaders
- Self-starter who can set own goals and direction with minimal supervision
- In accordance with the Discipline Engineering Corrosion Materials Competences for Shell, the role requires key mechanical static competencies as indicated below:
- K/S (knowledge/skill) is required in the following 4 areas:
- Materials Selection and Specification. [S]
- Corrosion Control System Design and Management. [K]
- Integrity and Repair Assessments. [K]
- Investigation of Equipment Failure. [K]
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